System and method for cutting roofing shingles

ABSTRACT

A system and method for cutting shingles according to which a plurality of cutting blades are mounted on the outer circumference of a cutting cylinder, and the cylinder is rotated with the blades engaging the sheet while effecting relative translational movement between the cylinder and the sheet so that shingles are cut from the sheet upon one rotation of the cylinder.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part application of pending U.S. application Ser. No. 10/613,152 filed Jul. 3, 2003.

BACKGROUND

This invention relates to a system and method for cutting individual objects, such as shingles, from a continuous sheet of material.

In the mass production of composition, or asphalt, roofing shingles, a cutting cylinder is often positioned to engage a continuous sheet of a composition material that forms the shingles. Cutting blades are provided on the outer circumference of the cutting cylinder and the continuous sheet of material is passed under the cylinder as it is rotated to cut the shingles. In order to produce an attractive pattern, shingles have been cut in a “dragon tooth” pattern. However, when dragon tooth patterns are cut, a lack of variance in shingle patterns result in a non-random appearance when the shingles are applied to a roof, resulting in a relatively unsightly patterned appearance when compared to individual wood shingles, and the like.

Therefore a system and method is needed to produce roofing shingles of the above type which are cut in a dragon tooth pattern yet increase product appearance when compared to the techniques discussed above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view depicting an embodiment of the system of the present invention.

FIG. 2 is an elevational view of eight shingles produced by the system of FIG. 1.

FIGS. 3A-3 d are views similar to that of FIG. 1 but depicting an alternate embodiment.

FIG. 4 is an elevational view of eight shingles produced by the system of FIGS. 3A-3D.

DETAILED DESCRIPTION

Referring to FIG. 1, the reference numeral 10 refers to a strip or sheet of material that is used to produce shingles in accordance with an embodiment of the invention. It is understood that the sheet 10 forms a portion of a continuous sheet which is described in detail later. The sheet 10 passes between two opposed cylinders 12 and 14 which are mounted for rotation in a conventional manner. One or both of the cylinders 12 or 14 is driven in any conventional manner to rotate the cylinders and drive the sheet 10 in a longitudinal direction indicated by the arrows while being guided by edge guides, or the like (not shown), all in a conventional manner.

A cutting blade 16 a is mounted on the outer circumference of the cylinder 12 and is adapted to cut the sheet 10 when it passes between the cylinders 12 and 14. The cutting blade 16 a extends for approximately one half the circumference of the cylinder, and a cutting blade 16 b is also mounted on the outer circumference of the cylinder and extends from the cutting blade 16 a around the remaining one half of the circumference of the cylinder.

A cutting blade 18 a is also mounted on the outer circumference of the cylinder 12 and extends in a spaced parallel relationship to the blades 16 a and 16 b for approximately one half the circumference of the cylinder 12. A cutting blade 18 b is also mounted on the outer circumference of the cylinder 12 and extends from the cutting blade 18 a and around the remaining one half of the circumference of the cylinder. A cutting blade 19 is also mounted on the outer circumference of the center portion of the cylinder 12 and extends around the entire circumference of the cylinder. Each cutting blade 16 a, 16 b, 18 a, and 18 b has a configuration that is different from the other blades and each blade extends for approximately one-half the circumference of the cylinder 12, or 180 degrees. The blades 16 a and 16 b are disposed in an end-to-end relationship so that they continuously cut the sheet 10 when it passes between the rotating cylinders 12 and 14. Likewise, the blades 18 a and 18 b are disposed in an end-to-end relationship so that they continuously cut the sheet 10 when it passes between the rotating cylinders 52 and 54. The cutting blades 16 a, 16 b, 18 a, 18 b and 19 are mounted on the cylinder 12 in any conventional manner.

The cutting blades 16 a, 16 b, 18 a and 18 b are configured to cut four different dragon tooth patterns in the sheet 10 upon one rotation of the cylinder 12. Each dragon tooth pattern produces two shingles with complementary tabs and spaces between the tabs, which will be described. Therefore one rotation of the cylinder 12 produces eight unique shingles.

During the cutting of the above patterns by the blades 16 a, 16 b, 18 a and 18 b, the center cutting blade 19 cuts the sheet 10 longitudinally to separate the patterns cut by the blades 16 a and 16 b from the patterns cut by the blades 18 a and 18 b. It is understood that an end cutter (not shown) can be provided downstream from, and in a spaced relation to, the cylinder 12 for making transverse cuts in the sheet to cut the sheets into predetermined lengths.

FIG. 2 shows examples of eight different shingles after being cut by the blades 16 a, 16 b, 18 a, 18 b and 19, and by the above end cutter in response to one rotation of the cylinder 12, with the shingles being shown spaced apart in the lateral and longitudinal directions. In particular, two shingles 20 and 22 are formed by the dragon tooth cut made by the blade 16 a. The shingle 20 includes four relatively narrow rectangular tabs 20 a, and the shingle 22 includes four relatively wide rectangular tabs 22 a.

Two shingles 24 and 26 are formed by the dragon tooth cut made by the blade 16 b. The dragon tooth pattern cut by the blade 16 b is such that the shingle 24 includes two relatively wide rectangular tabs 24 a which are wider than the wide tabs 22 a of the shingle 22; while the shingle 26 includes a tab 26 a that is wider than the tabs 24 a and a tab 26 b that is wider than the tab 26 a.

Similarly, two shingles 28 and 30 are formed by the dragon tooth cut made by the blade 18 a. The latter pattern is such that the shingle 28 includes a relatively wide rectangular tab 28 a extending between two relatively narrow tabs 28 b; while the shingle 30 is formed with three rectangular tabs 30 a of the same width as the tabs 28 b, with two of the tabs 30 a being spaced apart as a result of cutting the tab 28 a.

Two shingles 32 and 34 are formed by the dragon tooth cut made by the blade 18 b. The dragon tooth pattern cut by the blade 18 b is such that both shingles 32 and 34 include four triangularly shaped tabs 32 a and 34 a.

As a result of the above, one rotation of the cylinder 12 produces eight different shingles 20, 22, 24, 26, 28, 30, 32, and 34 all of which vary in appearance. Thus, when stacked and applied to a roof in sequence, a non-random, dimensional appearance is achieved rather than the unsightly patterned appearance of the prior art.

In FIGS. 3A-3D, the reference numeral 50 refers to a sheet of material that is used to produce shingles in accordance with another embodiment of the invention. It is understood that the sheet 50 forms a portion of a continuous sheet that passes between two opposed cylinders 52 and 54 which are mounted for rotation in a conventional manner. One or both of the cylinders 52 or 54 is driven in any conventional manner to rotate the cylinders and drive the sheet 50 in a longitudinal direction indicated by the arrows while being guided by edge guides, or the like (not shown), all in a conventional manner.

Four circumferentially-spaced cutting blades 56 a-56 d are mounted on the outer circumference of the cylinder 52 in any conventional manner. Each blade 56 a-56 d has a configuration that is different from the other blades, and each blade extends for approximately one-fourth the circumference of the cylinder, or for ninety degrees. The blades 56 a-56 d are disposed in an end-to-end relationship so that they, when taken together, extend around the entire circumference of the cylinder. Thus, when the sheet passes between the rotating cylinders 52 and 54, the blades 56 a-56 d sequentially engage and cut the sheet 50 to make a continuous longitudinal cut down the sheet to separate the sheet into two portions.

FIG. 3B depicts the cylinder 52 rotated approximately ninety degrees from its position in FIG. 3A; FIG. 3C depicts the cylinder rotated approximately ninety degrees from its position in FIG. 3B; and FIG. 3D depicts the cylinder rotated approximately ninety degree from its position in FIG. 3C. During this rotation, the cutting blades 56 a-56 d sequentially engage the sheet and cut the sheet 50 along a cutting line between the two side edges of the sheet and generally towards the center. Thus, upon one rotation of the cylinder 52, each blade 56 a-56 d cuts its one quarter portion of the sheet into two shingles extending to either side of the cut line. Since there are four cutting blades 52 a-52 d, one rotation of the cylinder 52 produces eight unique shingles.

It is understood that an end cutter (not shown) can be provided downstream from, and in a spaced relation to, the cylinder 52 for making transverse cuts in the sheet to cut the sheets into predetermined lengths.

FIG. 4 shows examples of eight different shingles 60 a-60 h after being cut by the blades 56 a-56 d and after they have been paced apart slightly in the lateral and longitudinal directions. Since the shingles 60 a-60 h are cut into the same patterns as discussed above in connection with the shingles 20, 22, 24, 26, 28, 30, 32, and 34, they will not be described in detail.

As a result of the above, one rotation of the cylinder 52 produces eight different shingles 60 a-60 h all of which vary in appearance. Thus, when stacked and applied to a roof in sequence, a non-random, dimensional appearance is achieved rather than the unsightly patterned appearance of the prior art mentioned above. It is understood that the method of applying the different patterned shingles 20, 22, 24, 26, 28, 30, 32, and 34 to a supporting structure to form a roof, as discussed above, is equally applicable to the shingles 60 a-60 h.

In each of the above embodiments the sheets 10 and 50 may be formed in a conventional manner, such as by applying one or two asphalt coatings to a base material made from a mat of organic felt, fiberglass, polyester, or a blended fiberglass/polyester, and applying one or two outer layers of mineral granules to the asphalt coating(s). Further details of the composition of the sheet 10 and the lamination technique are disclosed in U.S. Pat. No. 5,369,929 which is assigned to the assignee of the present invention and which is incorporated by reference. It is also understood that one or more backing sheets (not shown) can be laminated to the sheets 10 and 50 before the resulting laminated sheets are cut in the foregoing manner. The backing sheet may be identical to the sheets 10 and 50 or may be different from the latter sheets.

Variations

1. The above configurations and patterns of the cutting blades and the shingles are for the purpose of example only, and therefore can vary considerably from those that are shown in the drawings and described above.

2. The sizes and numbers of the cutting blades and the shingles as well as their width, length, and/or shape can vary from the examples shown in the drawings and described above.

3. The end cutter mentioned above can be provided on the cylinders rather than downstream from the cylinders.

4. One or both of the cylinders can be rotated in manners other than those described in the above embodiments.

5. The configurations of all the blades in each embodiment do not necessarily have to be different as long as at least a portion the blades are different.

6. The above-described relative movement between the cylinders and the sheets can be achieved in other manners.

7. The spatial references, such as “over,” “under,” “longitudinal,” “lateral,” and the like, are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.

Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. 

1. A system for cutting shingles from a continuous sheet of material, the system comprising: a cylinder; a series of cutting blades mounted on the cylinder; each blade extending for a portion of the circumference of the cylinder; the blades being disposed in an end-to-end relationship; the length of each blade being such that, when connected in the end-to-end relationship, the blades extend around the entire circumference of the cylinder; means for rotating the cylinder while effecting relative translational movement between the cylinder and the sheet so that the blades sequentially engage and cut the sheet to make a continuous longitudinal cut down the sheet to separate the sheet into two portions; and the configurations of at least a portion of the blades being different so that a corresponding number of shingles having different patterns are cut in the sheet upon each revolution of the cylinder.
 2. The system of claim 1 wherein there are four blades, each extending for approximately one-fourth of the circumference of the cylinder.
 3. The system of claim 1 further comprising means for making transverse cuts in the sheet to separate the shingles.
 4. The system of claim 1 wherein each blade cuts two shingles having interlocking tabs.
 5. The system of claim 4 wherein the blades are configured so that at least a portion of the tabs of each shingle are different from the tabs of at least a portion of the other shingles.
 6. The system of claim 4 wherein at least a portion of the tabs of the same shingle are different.
 7. A system for cutting shingles from a continuous sheet of material, the system comprising: a cylinder; a first series of cutting blades mounted on the cylinder with each blade extending for a portion of the circumference of the cylinder and the blades disposed in an end-to-end relationship, the length of each blade being such that, when connected in the end-to-end relationship, the blades extend around the entire circumference of the cylinder; a second series of cutting blades mounted on the cylinder and extending parallel to the first series, each blade of the second series extending for a portion of the circumference of the cylinder and the blades of the second series disposed in an end-to-end relationship, the length of each blade of the second series being such that, when connected in the end-to-end relationship, they extend around the entire circumference of the cylinder; an additional cutting blade extending over the circumference of the cylinder and adapted to make a continuous longitudinal cut down the center of the sheet to divide the sheet into two portions; means for rotating the cylinder while effecting relative translational movement between the cylinder and the sheet so that the first series of blades sequentially engage and cut one of the sheet portions to make a continuous longitudinal cut down the one sheet portion to separate the one sheet portions into two sections, and so that the second series of blades sequentially engage and cut the other sheet portion to make a continuous longitudinal cut down the other sheet portion to separate the other sheet portion into two sections; and the configurations of at least a portion of the blades being different so that a corresponding number of shingles having different patterns are cut in the sheet upon each revolution of the cylinder.
 8. The system of claim 7 wherein there are two spaced parallel series of cutting blades, each series extending over the entire circumference of the cylinder.
 9. The system of claim 8 wherein there are a first cutting blade extending over approximately one half of the circumference of the cylinder, a second blade extending from the first cutting blade and over approximately the other half of the circumference of the cylinder, a third cutting blade extending in a spaced parallel relationship to the first and second blades, and over approximately one half of the circumference of the cylinder, and a fourth blade extending from the third first cutting blade and over approximately the other half of the circumference of the cylinder.
 10. The system of claim 7 further comprising means for making transverse cuts in the sheet to separate the shingles.
 11. The system of claim 7 wherein each blade cuts two shingles having interlocking tabs.
 12. The system of claim 11 wherein the blades are configured so that at least a portion of the tabs of each shingle are different from the tabs of at least a portion of the other shingles.
 13. The system of claim 11 wherein at least a portion of the tabs of the same shingle are different.
 14. A method of cutting shingles from a continuous sheet of material, the method comprising: mounting a series of cutting blades in an end-to-end relationship on a cylinder so that each blade extends for a portion of the circumference of the cylinder and so that the blades together extend around the entire circumference of the cylinder; rotating the cylinder while effecting relative translational movement between the cylinder and the sheet so that the blades sequentially engage and cut the sheet to make a continuous longitudinal cut down the sheet to separate the sheet into two portions; and the configurations of at least a portion of the blades being different so that a corresponding number of shingles having different patterns are cut in the sheet upon each revolution of the cylinder.
 15. The method of claim 14 wherein there are four blades, each extending for approximately one-fourth of the circumference of the cylinder.
 16. The method of claim 14 further comprising making transverse cuts in the sheet to separate the shingles.
 17. The method of claim 14 wherein each blade cuts two shingles having interlocking tabs.
 18. A method of cutting shingles from a continuous sheet of material, the method comprising: mounting a first series of cutting blades on the cylinder in an end-to-end relationship so that each blade extends for a portion of the circumference of the cylinder and so that the blades together extend around the entire circumference of the cylinder; mounting a second series of cutting blades on the cylinder in an end-to-end relationship so that each blade in the second series extends for a portion of the circumference of the cylinder and so that the blades of the second series together extend around the entire circumference of the cylinder; cutting a continuous longitudinal cut down the center of the sheet to divide the sheet into two portions; rotating the cylinder while effecting relative translational movement between the cylinder and the sheet so that the first series of blades sequentially engage and cut one of the sheet portions to make a continuous longitudinal cut down the one sheet portion to separate the one sheet portions into two sections, and so that the second series of blades sequentially engage and cut the other sheet portion to make a continuous longitudinal cut down the other sheet portion to separate the other sheet portion into two sections; and the configurations of at least a portion the blades being different so that a corresponding number of shingles having different patterns are cut in the sheet upon each revolution of the cylinder.
 19. The method of claim 18 wherein there are two spaced parallel series of cutting blades, each series extending over the entire circumference of the cylinder.
 20. The method of claim 18 wherein there are a first cutting blade extending over approximately one half of the circumference of the cylinder, a second blade extending from the first cutting blade and over approximately the other half of the circumference of the cylinder, a third cutting blade extending in a spaced parallel relationship to the first and second blades, and over approximately one half of the circumference of the cylinder, and a fourth blade extending from the third first cutting blade and over approximately the other half of the circumference of the cylinder.
 21. The method of claim 18 further comprising making transverse cuts in the sheet to separate the shingles.
 22. The method of claim 18 wherein each blade cuts two shingles having interlocking tabs. 